Process Modeling Using HYSYS Two-Stage Compression

Two-Stage Compression

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 Process Modeling Using HYSYS Two-Stage Compression

Workshop
This example demonstrates a typical application of the recycle
operation. Feed gas enters the compressor station at 35°C (95°F) and
1725 kPa (250 psia). The gas is to be delivered at 6900 kPa, and it is to
be compressed in two stages. Each stage consists of a knockout drum,
a compressor, and a cooler. Liquids from each separator are recycled
back to the previous stage, after the pressure has been reduced.

Learning Objectives
Once you have completed this section, you will be able to:
• Use the recycle operation in HYSYS
• Choose suitable tear locations for recycles

Prerequisites
Before beginning this module you need to know how to add streams
and operations.

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 Process Modeling Using HYSYS Two-Stage Compression

Process Overview

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 Process Modeling Using HYSYS Two-Stage Compression

Building the Simulation

Defining the Simulation Basis
For this case, you will be using the Peng Robinson EOS with the
following components: N2 , CO2 , C1 , C2 , C3 , i-C4 , n-C4 , i-C5 , n-C5 ,
C6 .
Starting the Simulation
Add a new Material stream with the following values:

In this cell... Enter...

Name To Compression
Temperature, °C 35°C (95°F)
Pressure 1725 kPa (250 psia)
Molar Flow 5000 kgmole/h (11,000 lbmole/hr)
Component Mole Fraction
N2 0.0075
CO2 0.0147
C1 0.5069
C2 0.1451
C3 0.0725
i-C4 0.0652
n-C4 0.0578
i-C5 0.0515
n-C5 0.0431
C6 0.0357

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 Process Modeling Using HYSYS Two-Stage Compression

Build the Simulation without the

Recycle Operations
1. Install a Mixer with the following values:
In this cell... Enter...
Connections
Name Mixer 1
Inlet To Compression
Outlet To LP Sep
Parameters
Pressure Assignment Equalize All

2. Add a Separator with the information shown below:

In this cell... Enter...
Connections
Name LP Sep
Inlets To LP Sep
Vapor Outlet LP Sep Vap
Liquid Outlet LP Sep Liq

3. Add a Compressor with the following values:

In this cell... Enter...
Connections
Name Stage 1
Inlet LP Sep Vap
Outlet Stage 1 Out
Energy Stage 1 HP
Parameters
Adiabatic Efficiency 75% (default)
Worksheet
Stage 1 Out, Pressure 3450 kPa (500 psia)

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 Process Modeling Using HYSYS Two-Stage Compression

4. Install a Cooler with the values listed in the following table:

In this cell... Enter...
Connections
Name Stage 1 Cooler
Inlet Stage 1 Out
Outlet Cooler 1 Out
Energy Stage 1 Q
Parameters
Pressure Drop 0 kPa
Worksheet
Cooler 1 Out, Temperature 50°C (125°F)

5. Add a Mixer operation to your case.

In this cell... Enter...
Connections
Name Mixer 2
Inlet Cooler 1 Out
Outlet To IS Sep
Parameters
Pressure Assignment Equalize All

6. Install a Separator with the following information:

In this cell... Enter...
Connections
Name IS Sep
Inlet To IS Sep
Vapor Outlet IS Sep Vap
Liquid Outlet IS Sep Liq

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 Process Modeling Using HYSYS Two-Stage Compression

7. Add a Valve with the following information.

In this cell... Enter...
Connections
Name LetDown 1
Inlet IS Sep Liq
Outlet LD1 Out
Worksheet
LD1 Out, Pressure 1725 kPa (250 psia)

8. Install a Compressor with the values shown below:

In this cell... Enter...
Connections
Name Stage 2
Inlet IS Sep Vap
Outlet Stage 2 Out
Energy Stage 2 HP
Parameters
Adiabatic Efficiency 75% (default)
Worksheet
Stage 2 Out, Pressure 6900 kPa (1000 psia)

9. Install a Cooler operation to the case.

In this cell... Enter...
Connections
Name Stage 2 Cooler
Inlet Stage 2 Out
Outlet Cooler 2 Out
Energy Stage 2 Q
Parameters
Pressure Drop 0 kPa
Worksheet
Cooler 2 Out, Temperature 50°C (125°F)

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 Process Modeling Using HYSYS Two-Stage Compression

10 Add a Separator with the following values:

In this cell... Enter...
Connections
Name HP Sep
Inlet Cooler 2 Out
Vapor Outlet HP Sep Vap
Liquid Outlet HP Sep Liq

11. Install a Valve with the following information:

In this cell... Enter...
Connections
Name LetDown 2
Inlet HP Sep Liq
Outlet LD2 Out
Worksheet
LD2 Out, Pressure 3450 kPa (500 psia)

The only operations missing at this point are the Recycles.

Installing the Recycles

A recycle operation is a mathematical unit operation and is installed as
any other. It has an inlet (calculated) stream and an outlet (assumed)
stream. The operation is called/calculated whenever changes to the
inlet stream fall outside of the converged tolerance.
The Recycle installs a theoretical block in the process stream. The feed
into the block is termed the calculated recycle stream, and the product
is the assumed recycle stream. The following steps take place during
In general, a Recycle the convergence process
operation is required for • HYSYS uses the conditions of the assumed stream (outlet) and
material transfer and not
for thermal recycles.
solves the flowsheet up to the calculated stream (inlet).
• HYSYS then compares the values of the calculated stream to
Always supply a guess or those in the assumed stream.
starting point for the
outlet stream of the
Recycle, never the inlet.
A guess close to the
solution will result in a
faster convergence time.

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 Process Modeling Using HYSYS Two-Stage Compression

• Based on the difference between the values, HYSYS modifies

the values in the calculated stream and passes the modified
values to the assumed stream.
• The calculation process repeats until the values in the
calculated stream match those in the assumed stream within
specified tolerances.
Examine streams LD1 Out and LD2 Out. Can these be used as the guess for the Recycle
outlet?____________________________________________________

LD1 Out LD2 Out

Temperature

Pressure

Flow

Is Composition Known?

Notice that both LetDown Valve outlets (also the Recycle Inlets) are
known. This will be a good starting point for the Assumed stream (or
guess of the Recycle).
1. Add the first Recycle by double-clicking on the Recycle icon in the
Recycle icon
Object Palette.

Connections Page
2. Supply the Name, Feed and Product information as shown in the
figure:

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 Process Modeling Using HYSYS Two-Stage Compression

Parameters Tab
Tolerance Page

The smaller the tolerance

value, the tighter the
tolerance. Generally it is
a good idea to start with
the default tolerance until
you have a converged
solution and then tighten
the tolerance.

HYSYS allows you to set the convergence criteria or tolerance for

each of the Recycle variables. In addition, the direction of transfer of
information can be set to Forwards or Backwards, or Not Transferred
at all. In general you will want to leave the transfer as Forwards. In
this example, leave everything at the default.
Numerical Page
This page contains the options for the two types of Recycles, Nested
and Simultaneous.
• Nested. This type of recycle gets called whenever it is
encountered during calculations. Use this type if you have a
single Recycle or if you have multiple recycles which are not
connected.
• Simultaneous. All recycles set at Simultaneous will be called
at the same time. Use this option if your Flowsheet has
multiple inter-connected recycles.

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 Process Modeling Using HYSYS Two-Stage Compression

In this case, we will use Nested Recycles.

Monitor Tab
This page displays convergence information as the calculations are
performed. Any variable that changes between iterations is displayed
in this table. In order to view plots of variables as they change during
the calculation of the recycle, you must select the variables to view on
the Setup page.
Worksheet Tab
The Recycle Worksheet page displays the Inlet and Outlet stream
information. In this instance, notice that the Inlet and Outlet streams
have the same values. This is because before we installed the Recycle,
the Inlet stream was already calculated by HYSYS. When the Recycle
was connected, the known Inlet conditions were automatically passed
to the Outlet stream to serve as the starting guess.
3. Install the second Recycle with the following information:
In this cell... Enter...
Connections
Inlet LD2 Out
Outlet RCY 2 Out

The final step to solving the flowsheet is to connect the Recycle

Outlets as Inlets to Mixer1 and Mixer2. Once this is done, the
flowsheet will begin solving.
4. Attach RCY 1 Out as a feed to Mixer 1.
5. Attach RCY 2 Out as a feed to Mixer 2.

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 Process Modeling Using HYSYS Two-Stage Compression

Optional

Analyzing the Results

If you saved your case as a template, close the template and open the
saved case.
Examine the convergence process for the Recycles. Open the Recycle
property view and look at the Monitor tab. How many iterations did
each Recycle need to converge?
Look at the Worksheet tab for each Recycle. How close are the Inlet and Outlet stream
variables?______________________________________________

Are the vapor fractions identical for the Inlet and

Outlet?______________________________________________________________

RCY 1 RCY 2
Inlet Vf
Outlet Vf

If the vapor fractions are slightly different, tighten the composition tolerance (change the
tolerance from 10.0 to 1.0). Does this make any
difference?__________________________________________________________

Advanced Modeling
Because the Recycle operation is a mathematical representation of a
physical process, its location in a simulation is a particularly important
one. The location of the tear stream can often determine success or
failure to converge a recycle.
Choose a Tear Location to Minimize the
Number of Recycles
Reducing the number of locations where the iterative process is
required will save on the total convergence time. Choosing the
location of the Recycle will depend on the Flowsheet topology.
Attempt to choose a point such that specifying the assumed stream will
define as many streams downstream as possible. It generally occurs

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 Process Modeling Using HYSYS Two-Stage Compression

downstream of gathering points (mixers) and upstream of distribution

points (tees, separators, and columns).
Choose a Tear Location to Minimize the
Number of Recycle Variables
Variables include vapor fraction, temperature, pressure, flow,
enthalpy, and composition. Choose the tear stream so that as many
variables as possible are fixed, thus effectively eliminating them as
variables and increasing convergence stability. Good choices for these
locations are at separator inlets, compressor after cooler outlets, and
A very poor choice of
a tear stream is a
trim heater outlets.
stream with an Adjust
operation controlling Choose a Stable Tear Location
one of its variables. The tear locations can be chosen such that fluctuations in the recycle
stream have a minimal effect. For example, by placing the tear in a
main stream, instead of the physical recycle, the effect of fluctuations
will be reduced. The importance of this factor depends on the
convergence algorithm. It is more significant when successive
substitution is used.

Exploring the Simulation

Exercise 1: Adding a Recycle
Where should the Recycle be placed in this flowsheet and why?

Where should the Recycle be placed in this flowsheet and why?____________

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 Process Modeling Using HYSYS Two-Stage Compression

Assume that the Feed is fully defined, Shell and Tube Side pressure
drops are known, as well as the Column Feed temperature.

Where should the Recycle be placed in this flowsheet and why? _____

Assume the Feed is completely defined, shell and tube side pressure
drops for E-100 and E-101, and the temperatures of streams 3 and 4
are known.

Where should the Recycle be placed in this flowsheet and why?_____

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 Process Modeling Using HYSYS Two-Stage Compression

Assume the Feed is completely defined, and the shell and tube side
pressure drop for E-100 are known.

Exercise 2: Compressor Outlet Pressure

After finishing the simulation, your boss provides you with a set of
Compressor Curves for the Stage 2 Compressor, which now exists in
the field. Will the existing Compressor be able to achieve the outlet
pressure you want (i.e., 6900 kPa), or will you have to add a third
stage of compression?
Flow, ACT [m3/min (ACFM)] Head [m (ft)] Polytropic Efficiency
30 (1000) 6000 (19670) 74
55 (2000) 5950 (19500) 75
95 (3400) 5800 (19000) 75.25
140 (5000) 5500 (18000) 74.5
175 (6200) 4800 (15700) 72
205 (7300) 3360 (11000) 68

Challenge
You complain to your boss, Polly Sim that your simulation takes too
long to converge on your computer because of the recycles and use
this opportunity to petition for a new high-speed computer. Polly has a
look at your simulation and denies your request on the basis that you
can reduce your convergence time by eliminating one of the recycles
in the simulation. Is your request justified or is Polly correct?

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 Process Modeling Using HYSYS Two-Stage Compression

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